Method for combining a tensioned elastic garter with a substrate

ABSTRACT

A method for bonding a tensioned elastic garter to a substrate while holding the garter in a predetermined shape. A garter is any continuous loop of elastic material or a laminate of elastic bands and one or more flexible backing sheets. In one embodiment a mandrel has a top surface and side walls. The side walls have recesses. A tensioned garter is wrapped around the side walls such that it spans the recesses. A substrate is placed against the top surface of the mandrel. An anvil surface is positioned to backup the substrate. Sealing tools pass through the recesses and intercept the tensioned garter and press it against the substrate backed up by the anvil surface. Thermobonding or adhesive sealing occur at spots where sealing tools press the tensioned garter against the substrate and anvil. The garter is stripped from the mandrel either by moving the substrate away from the mandrel or by having the sealing tools push the garter off the mandrel side walls. Portions of the garter between sealing spots take straight line paths once released from the garter.

CROSS-REFERENCE TO RELATED APPLICATION

This is a divisional application Ser. No. 08/132,730, entitled: METHODAND APPARATUS FOR COMBINING A TENSIONED ELASTIC GARTER WITH A SUBSTRATE,filed on Oct. 6, 1993, which has issued as U.S. Pat. No. 5,393,360 onFeb. 28, 1995.

FIELD OF THE INVENTION

The present invention relates to a process for elasticizing an articleby bonding a tensioned elastic member to it, and more particularly to aprocess wherein the elastic member is a garter stretched in more thanone direction and the article is a substrate. Even more particularly,the present invention relates to a process wherein a tensioned elasticgarter is held in a predetermined shape by a mandel as it is bonded to asubstrate.

BACKGROUND OF THE INVENTION

Elasticizing a flexible substrate, such as a sheet of cloth or plasticfilm, may be accomplished by attaching a tensioned elastic member to it.When the elastic member is allowed to contract, the flexible articlewrinkles or shirrs to contract in dimension along with the elasticmember. The article can subsequently be stretched as though it wereitself elastic. This concept is used, for example, in the manufacture ofdisposable diapers to provide elastic leg cuffs for snug,leak-resistant, body fit.

There are many commercial processes for combining elastic members withsubstrate materials. However, reliably combining tensioned elastics witha continuously moving substrate web, as is required in high speeddiaper-making systems, has required relatively complex methods andapparatii.

If, for example, elasticity is needed only in machine direction (thedirection of travel of a continuously moving web), a continuous elasticribbon may be fed parallel to the direction of substrate web travel froma source metering the elastic ribbon at a lower rate of speed than thespeed of the substrate web. As the elastic ribbon is progressivelybonded to the substrate web in the nip of a pair of sealing rolls, theelastic is stretched between its metering source and the sealing rolls.It is stretched an amount depending on the speed differential betweenthe substrate web and the elastic ribbon metering rolls. This representsone of the simplest processes for combining elastics with moving webs.

Where tensioned elastics are applied in cross machine direction or atsome other angle to machine direction, more complex systems have beenrequired. For example, the substrate web may be passed through a festoonsystem whereby the continuously moving web is effectively indexed. Thatis, the substrate web is stopped for a short time along a portion of itspath while the remainder of the web continues to move within a series ofaccumulation rolls. An elastic ribbon may then be sequentially stretchedand bonded in any direction to the temporarily stationary portion of theweb.

Where elasticity is desired in curved profiles, such as in elasticizeddiaper leg cuffs, even more complex processes have been required. Forexample, an elastic ribbon may be tensioned and then heat deactivated tocause it to become inelastic after it has been elongated. The inelasticribbon may then be profiled, such as by camming the ribbon in asinusoidal fashion perpendicular to machine direction as the ribbon isbonded to a substrate web. Because the elastic property is deactivated,the ribbon can be handled without concern for contraction forcesdisrupting the curved profile before and during bonding. Later, afterthe shaped elastic has been bonded to the substrate web, a separate heatreactivation step reestablishes the elasticity of the profiled ribbon.Because of the need for heat deactivation and reactivation, elasticmaterial choices are limited. Such processes are complicated by the factthat whenever heat is applied to polymer elastic materials, thetemperature must be accurately controlled to avoid interfering withelastic properties. Also, the important properties of spring rate andpercent stretch that are available for heat reactivated elasticmaterials are less than those available for elastics which are notreactivated with heat.

Diaper elastic members are typically either polymer ribbons or laminatesof multiple polymer strands combined with nonwoven sheets. Where anelastic member forms a continuous loop with no ends, the elastic memberis defined as a garter. Elastic members may generally be bonded tosubstrates in high speed continuous processes by fusion-sealing,heat-activated adhesive sealing, or pressure sensitive adhesive sealingmethods. These methods are more generally classified as thermal bondingand adhesive bonding.

Where a garter is stretched circumferentially and bonded to a substrateto create an elasticized opening, it may be necessary to removesubstrate material from inside the garter if a hole was not firstcreated in the substrate before bonding.

Commercial processes for removing substrate material inside a garterhave generally followed the steps of folding the substrate along amachine direction axis passing through the center of the pattern andthen cutting out the substrate material inside the pattern byprogressively cutting from the folded edge inward and then back to thefolded edge. Although progressive cutting can be done at high speeds byrotary knives, by water jet, or by laser, these are all expensiveconverting processes. Also hole symmetry about the fold axis isgenerally required since both sides of a hole are cut simultaneously.

Diaper leg cuffs are of ten made by abutting two or more elasticizedpatterns which form less than a full loop. They are joined in order tocreate a full loop; however, such a composite loop does not havecontinuous elastics and therefore does not have the capability ofdistributing the stretch equally around the loop. Only continuous garterelastics have this capability, which is desired for optimum fit. Legcuffs made by creating a tensioned garter are superior to leg cuffs madeby other means of elasticization.

In light of the complexity of known processes for combining tensionedelastic members with moving substrates, and the need for generatingdiaper leg cuffs made of tensioned garters bonded to a moving substrate,it is an object of the present invention to combine tensioned garterswith a continuously moving substrate in a process that simplifiesstretching the garter in multiple directions and holding the tensionedgarter in a predetermined shape while bonding it to the substrate.

It is a further object of the present invention to bond tensionedgarters to a substrate while simultaneously creating a weakened zone atan edge of the garter bond for removal of the material inside thegarter, without the need for folding the substrate or introducingexternal heat to the materials.

SUMMARY OF THE INVENTION

In one preferred embodiment, the present invention provides a method ofcombining a tensioned garter with a substrate. A tensioned garter iswrapped about a mandrel. The mandrel has a top surface and side wallsdepending from the top surface. The top surface has a perimeter defininga predetermined shape of the tensioned garter wrapped about the mandrel.The tensioned garter has an upper portion and a lower portion. Asubstrate is placed against the top surface of the mandrel. Thesubstrate is secured to the tensioned garter while the tensioned garteris held by the mandrel in the predetermined shape. The securing stepenables the tensioned garter to be stripped from the mandrel side wallswhen the substrate is moved away from the top surface of the mandrel. Aportion of the substrate is removed from within the predetermined shapeof the tensioned garter to form a hole around which the tensioned gartermay contract.

In this preferred embodiment the upper portion of the tensioned garteris positioned above the top surface of the mandrel. The upper portion ofthe tensioned garter has sufficient tension to cause the upper portionof the garter to fold over onto the top surface of the mandrel to form agarter flange while the lower portion of the tensioned garter clings tothe side walls of the mandrel. The step of securing the substrate to thetensioned garter in this embodiment includes passing the substrate,which lies against the garter flange, under an ultrasonic horn. The topsurface of the mandrel acts as an anvil between which the ultrasonichorn presses the garter flange and the substrate together while applyingvibration energy to form a fusion-seal therebetween. The top surface ofthe mandrel has a raised outer rim to provide a continuous fusion-sealat the outer rim. The outer rim has a shape against which the ultrasonichorn presses, which is adapted to weaken an edge of the continuousfusion-seal so that the edge of the fusion-seal which is weakened may bebroken to remove from inside the fusion-seal a portion of the substrateand of the tensioned garter, thereby forming a hole around which aremaining portion of the tensioned garter may contract.

This embodiment further includes the step of stripping the tensionedgarter from the mandrel while applying vacuum to the portion of thesubstrate inside the fusion-seal from the top surface of the mandrel sothat the edge of the continuous fusion-seal is broken when the substrateand the remaining portion of the tensioned garter are stripped off themandrel. The portion of the substrate broken away from the substrate isheld by vacuum to the top surface of the mandrel until after the hole iscompletely formed in the substrate.

Another preferred embodiment of the present invention is similar to thefirst one except that the step of securing the substrate to thetensioned garter is altered. A hole is cut in the substrate prior toplacing the substrate against the top surface of the mandrel. The holehas a shape smaller than the garter flange. The hole in the substrate isaligned with the mandrel so that the hole lies inside the garter flange.The substrate lying against the garter flange is passed under a sealingroll. The mandrel acts as an anvil against which the sealing rollpresses the garter flange and the substrate. The garter flange is sealedto the substrate. The substrate may be secured to the tensioned garterby thermal sealing or adhesive sealing.

In another preferred embodiment of the present invention the step ofsecuring the substrate to the tensioned garter is performed in aslightly different manner than previously set forth. The tensionedgarter is positioned on the mandrel below the top surface and about theside walls of the mandrel. The side walls have recessed portions acrosswhich the tensioned garter spans. The substrate is backed with an anvilsurface opposing the mandrel top surface. The tensioned garter isintercepted with sealing tools at locations where the tensioned garterspans the recessed portions of the side walls. The tensioned garter ispressed against the substrate backed by the anvil surface to enablesecurement of the tensioned garter to the substrate by a sealing meanswherever pressing by the sealing tools occurs.

In yet another preferred embodiment, the present invention provides amethod of making individual tensioned garters having a predeterminedshape. A first tensioned elastic ribbon and a second tensioned elasticribbon are metered tangentially toward a plurality of mandrels, eachspaced apart by a gap along a common centerline. Each of the mandrelshas a top surface and side walls depending therefrom. The first andsecond tensioned elastic ribbons are clamped between the mandrels bypushing the first tensioned elastic ribbon toward the common centerlineand by pushing the second tensioned elastic ribbon toward the commoncenterline, thereby encircling the side walls of each of the mandrels asthe first and second tensioned elastic ribbons meet at the commoncenterline. The first and second tensioned elastic ribbons are sealedtogether where they are clamped in order to form a ribbon seal betweeneach of the mandrels. The first and second tensioned elastic ribbons arecut within the ribbon seal between each of the mandrels so that whencut, the tensioned elastic ribbons form individual tensioned gartersabout the side walls of each of the plurality of mandrels. The commoncenterline of mandrels may be wrapped circumferentially around arotating drum so that the clamping step may occur progressively as thedrum rotates. Also, each of the mandrels may be pivoted on radial shaftsextending from the drum.

In this preferred embodiment the first and second tensioned elasticribbons may be trilaminates having outer nonwoven layers and a pluralityof elastic strands stretched longitudinally and intermittently bondedtherebetween. The bonding of the plurality of elastic strands to theouter nonwoven layers is interrupted at unbonded locations equallyspaced along the first and second tensioned elastic ribbons. The spacingof the unbonded locations corresponds to the gaps spacing apart themandrels. Each of the first and second tensioned elastic ribbons at theunbonded locations is compressed sufficiently to cause the plurality ofelastic strands between the outer nonwoven layers to burst and contractto where they are sealed without cutting the outer nonwoven layers, sothat the unbonded locations have no elastic strands within them. and Theunbonded locations of the first and second tensioned ribbons isregistered to the gaps spacing apart the mandrels when the first andsecond tensioned elastic ribbons are metered tangentially toward theplurality of mandrels.

In yet another preferred embodiment, the present invention provides anapparatus for combining a tensioned garter with a substrate. Theapparatus includes a mandrel having a top surface and side wallsdepending from the top surface. The apparatus also includes means forwrapping a tensioned garter about the mandrel. The top surface of themandrel has a perimeter defining a predetermined shape of the tensionedgarter. The tensioned garter has an upper portion and a lower portion.The apparatus also includes means for placing a substrate against thetop surface of the mandrel and means for securing the substrate to thetensioned garter while the tensioned garter is held by the mandrel in apredetermined shape.

In this preferred embodiment the means for securing the substrate to thetensioned garter includes means for positioning the upper portion of thetensioned garter above the top surface of the mandrel. The upper portionof the tensioned garter has sufficient tension to cause the upperportion to fold over onto the top surface of the mandrel to form agarter flange while the lower portion of the tensioned garter clings tothe side walls of the mandrel. The means for securing the substrate tothe tensioned garter also includes means for sealing the substrate tothe garter flange using the top surface of the mandrel as a sealinganvil. The means for sealing the substrate to the tensioned gartercomprises an ultrasonic horn adapted to press against the sealing anvilwith the substrate and the garter flange positioned therebetween. Theultrasonic horn applies vibration energy to form a fusion-seal betweenthe substrate and the garter flange.

In this preferred embodiment there is a raised outer rim on the topsurface of the mandrel. The raised outer rim provides a continuousfusion-seal at the outer rim. The outer rim has a shape against whichthe ultrasonic horn presses, which is adapted to weaken an edge of thecontinuous fusion-seal inside the fusion-seal so that the edge of thefusion-seal which is weakened may be broken. Breaking the weakened edgeof the fusion-seal enables removing from inside the fusion-seal aportion of the substrate and of the tensioned garter to form a holearound which a remaining portion of the tensioned garter may contract.There is also means provided for stripping the tensioned garter from themandrel while simultaneously applying vacuum to the portion of thesubstrate inside the fusion-seal from the top surface of the mandrel sothat the weakened edge of the fusion-seal is broken when the substrateand the tensioned garter are stripped off the mandrel.

In still another preferred embodiment of the present invention thereinis provided an apparatus for making individual tensioned garters havinga predetermined shape. The apparatus includes a plurality of mandrelsspaced apart along a common centerline, each of the mandrels having topsurfaces and side walls depending therefrom. The apparatus includesmeans for metering a first tensioned elastic ribbon and a secondtensioned elastic ribbon tangentially toward the plurality of mandrels.The apparatus includes means for clamping the first and second tensionedelastic ribbons between the plurality of mandrels by pushing the firsttensioned elastic ribbon toward the common centerline and by pushing thesecond tensioned elastic ribbon toward the common centerline, therebyencircling the side walls of each of the mandrels as the first andsecond tensioned elastic ribbons meet at the common centerline. Theapparatus includes means for sealing the first and second tensionedelastic ribbons together where they are clamped in order to form asealed region between each of the plurality of mandrels and means forcutting through the first and second tensioned elastic ribbons withinthe sealed region between each of the plurality of mandrels so that whencut, the tensioned elastic ribbons form individual tensioned gartersabout the side walls of each of the plurality of mandrels. The commoncenterline of mandrels may be wrapped circumferentially around arotating drum so that the clamping step may occur progressively as thedrum rotates. Also, each of the mandrels may be pivoted on radial shaftsextending from the drum.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims which particularly pointout and distinctly claim the present invention, it is believed that thepresent invention will be better understood from the followingdescription of preferred embodiments, taken in conjunction with theaccompanying drawings, in which like reference numerals identifyidentical elements and wherein:

FIG. 1a is a simplified perspective view of a preferred embodiment ofthe method and apparatus for combining a tensioned elastic garter with asubstrate of the present invention, disclosing a garter wrapped about anoval mandrel;

FIG. 1b is a front elevational view of the embodiment of FIG. 1a,without the garter, showing the angle between mandrel top surface andits depending side walls;

FIG. 2 is a simplified perspective view of the embodiment of FIG. 1a,showing the upper portion of the elastic garter folded over the topsurface of the mandrel to form a garter flange;

FIG. 3 is a simplified perspective view of the embodiment of FIG. 2,showing a substrate brought into contact with the garter flange;

FIG. 4 is a simplified perspective view of the embodiment of FIG. 3,showing an ultrasonic horn bonding the substrate to the garter flange;

FIG. 5 is an enlarged partial front elevation section view, taken alongsection line 5--5 of FIG. 4, showing the interface between ultrasonichorn, substrate, tensioned elastic garter, and mandrel during the stepof sealing the garter flange to the substrate and weakening the bond atthe edge of the seal;

FIG. 6 is a simplified perspective view of the embodiment of FIG. 4,showing the substrate and garter stripped off the mandrel, while aportion of the substrate and a portion of the garter flange inside thegarter are held to the mandrel by vacuum;

FIG. 7 is a simplified perspective view of an alternative embodiment ofthe method and apparatus for combining a tensioned elastic garter with asubstrate of the present invention, disclosing a substrate having apre-cut hole;

FIG. 8 is a simplified perspective view of the embodiment of FIG. 3,disclosing the substrate with pre-cut hole aligned with the garterflange formed on the mandrel;

FIG. 9 is a simplified perspective view of the embodiment of FIG. 8,disclosing a sealing roll bonding the substrate to the garter flange;

FIG. 10 is a simplified perspective view of the embodiment of FIG. 9,disclosing the stripping of the substrate and garter from the mandrel;

FIG. 11 is a simplified perspective view of an alternative embodiment ofthe method and apparatus for combining a tensioned elastic garter with asubstrate of the present invention, disclosing a garter formed about amandrel having recesses in its sides, and showing the garter spanningacross the side recesses;

FIG. 12 is a simplified perspective view of the embodiment of FIG. 11,showing a substrate brought into contact with the top of the mandrel;

FIG. 13a is a simplified perspective view of the embodiment of FIG. 12,showing an anvil placed on top the substrate above the mandrel topsurface, thereby sandwiching the substrate between the mandrel topsurface and the anvil;

FIG. 13b is a front elevational view of the embodiment of FIG. 13a,showing sealing tools pushing the portion of the garter spanning themandrel recesses upward against the substrate backed by the anvil;

FIG. 14a is a simplified perspective view of the embodiment of FIG. 13a,showing the garter sealed to the substrate only at sealing toollocations, and the unsealed portions of the garter assuming straightline chords between seals after the garter and substrate are removedfrom the mandrel;

FIG. 14b is a front elevational view of the embodiment of FIG. 14a,showing the anvil removed and the sealing tools stripping the substrateand garter from the mandrel;

FIG. 15 is a top plan view of five mandrels having garters formed aboutthem in a progressive fashion;

FIG. 16 is a perspective view of a rotating drum having mandrels spacedabout it, illustrating a preferred apparatus and method of the presentinvention;

FIG. 17 is a side elevational view of a mandrel mounted to a rotatingdrum, illustrating the tangential elastic ribbon metering and clampingprocess of FIG. 16;

FIG. 18 is a sectioned front elevational view, taken along section line18--18 of FIG. 17, showing elastic ribbons entering between mandrel andclamps;

FIG. 19 is an enlarged partial view of FIG. 18, showing a preferredelastic ribbon construction located relative to the mandrel;

FIG. 20 is a sectioned plan view, taken along section line 20--20 ofFIG. 7, showing the ribbon clamping, sealing, and cutting device;

FIG. 21a is a simplified perspective view of an alternative embodimentof the method and apparatus of FIG. 15, showing a tensioned elasticribbon being compressed between a blunt tool and an anvil surface; and

FIG. 21b is a simplified perspective view of the tensioned elasticribbon of FIG. 21a, showing elastic strands within a small area of thetensioned elastic ribbon having been burst and contracted.

DETAILED DESCRIPTION OF THE INVENTION First Preferred Embodiment

Referring now to the drawings, and more particularly to FIGS. 1a-6,there is shown a first preferred embodiment of the present invention,which provides a method and apparatus for combining a tensioned elasticgarter with a substrate, and is generally indicated as 30. Embodiment 30includes a mandrel 32, which has a top surface 34 and side walls 36depending from top surface 34. Top surface 34 is generally oval inshape, however top surface 34 may have any planar convex shape which hasno concave portions. FIG. 1b shows top surface 34 to be substantiallyplanar and that side walls 36 depend from the top surface 34 at an angle37. Preferably, the angle 37 is at least 270°.

FIG. 1a shows a tensioned elastic garter 38 wrapped around mandrel 32.Elastic garter 38 has a lower portion 40 and an upper portion 42. Lowerportion 40 clings tightly to side walls 36 of mandrel 32 due to thetension in the garter. FIG. 1a shows elastic garter 38 positioned withupper portion 42 above top surface 34 of mandrel 32. In this position,the tension in upper portion 42 of elastic garter 38 causes the upperportion 42 to fold onto top surface 34 in order to relieve some of thetension in upper portion 42, as shown in FIG. 2. Thus, FIG. 2 representsthe stable condition of tensioned elastic garter 38 when it ispositioned with its upper portion 42 above top surface 34 and its lowerportion 40 wrapped around mandrel 32. In this condition upper portion 42takes the form of an inward facing garter flange 44.

FIG. 3 shows a substrate 54 placed against the garter flange 44.Substrate 54 is shown as transparent for illustration purposes, but itmay be made of any material which is sealable to the material of garterflange 44. Substrate 54 is preferably a nonwoven polypropylene. FIG. 3shows substrate 54 in sheet form, but it may also be a continuous web.Garter 38 is preferably made of two nonwoven polypropylene strips, orone wide strip folded into two halves, which are bonded to multiplestrands of elastic sandwiched between them by intermittent glue stripes.The elastic strands, not shown, are preferably parallel to one anotherand oriented circumferentially within the elastic garter. However,elastic garter 38 may also be a solid ribbon of elastic material, suchas natural rubber, manufactured by Fulflex Company, located inBurlington, Vt.

FIG. 4 shows an ultrasonic sealing horn 56 in contact with substrate 54and positioned perpendicular to the top surface 34 of mandrel 32.Passing the top surface 34 of mandrel 32 under vibrating ultrasonic horn56 enables ultrasonic horn 56 to progressively fusion-seal substrate 54to garter flange 44, using top surface 34 of mandrel 32 as an anvil.Garter flange 44 and substrate 54 remain fixed relative to mandrel topsurface 34 during the bonding process. Vibration energy, which melts theinterface between substrate 54 and garter flange 44, is delivered byvibrating horn 56 from a source not shown. A fusion-seal 46 betweengarter flange 44 and substrate 54 is thereby generated.

FIG. 5 shows the ultrasonic fusion bonding process in more detail.Mandrel 32 may preferably have a substantially planar top surface 34, asshown in FIG. 1b, if sufficient sealing energy can be applied togenerate a seal the width of the garter flange. More preferably, topsurface 34 has a raised outer rim 58 which extends above top surface 34.Rim 58 provides a focal point for ultrasonic vibration energy from horn56 so that a fusion-seal 46 is formed between substrate 54 and garterflange 44 only where rim 58 supports garter flange 44.

An elastic garter may be bonded to a substrate with or without anopening inside the garter flange. It is preferable to have an openingaround which the garter may contract. If an opening has been provided inthe substrate prior to sealing, registration of the opening to thegarter flange is required. More preferably an opening is created aftersealing, and as part of the sealing process. Therefore, rim 58preferably has a peak 60 at its upper surface, rising slightly above rim58. Peak 60 acts to thin the seal between garter flange 44 and substrate54. Where seal 46 is so thinned, it is weakened relative to the rest ofthe seal. Thus, outer rim 58 has a shape adapted to fusion-seal thegarter flange 44 to the substrate 54, but with an edge of the sealweakened enough that material inside the continuous seal 46 can later beremoved by stressing the weakened center enough to break it. Mandrel 32is shown having a vacuum hole 48 connected to a vacuum source not shown.The purpose of vacuum hole 48 is discussed hereinafter.

Outer rim 58 and peak 60 are preferably continuous around the perimeterof top surface 34 of mandrel 32. If rim 58 were discontinuous, the sealbetween garter flange 44 and substrate 54 would also be discontinuous.Having a discontinuous sealing pattern for an elastic garter, combinedwith a process for cutting the garter between seals, would enableattaching independently functional, tensioned elastics to a substrate inboth machine direction and cross direction with one bonding step.

FIG. 6 shows the substrate 54 stripped from mandrel 32, carryingtensioned elastic garter 38 with it. The ultrasonic fusion-seal formedat rim 58 is strong enough to pull the lower portion 40 of garter 38from side walls 36 when substrate 54 is lifted from top surface 34 ofmandrel 32. The weakened part of fusion-seal 46 at peak 60 is weakenough that material 62, a portion of the substrate and of the garterflange inside the fusion-seal, is easily broken away from the strongpart of the fusion-seal if material 62 is held against top surface 34 ofmandrel 32 as the substrate 54 is stripped away.

Material 62 is preferably held to top surface 34 by a vacuum from holes48 in top surface 34, the source of which is not shown. By the processof simultaneously stripping the substrate 54 from the mandrel 32 andholding the material 62 to the mandrel, a hole 64 is created insubstrate 54 around which tensioned garter 38 may contract, therebyforming an elasticized opening in substrate 54.

Second Preferred Embodiment

In FIGS. 7-10, there is shown a second preferred embodiment of thepresent invention, which provides a method and apparatus for combining atensioned elastic garter with a substrate, and is generally indicated as80. Embodiment 80 includes a mandrel and a sealing roll. It accommodatesa substrate 82, which has a pre-cut hole 84, as is shown in FIG. 7.

FIG. 8 shows a garter 86 wrapped about a mandrel 88. Mandrel 88 has atop surface 90 which has side walls 92 depending therefrom, similar tothe mandrel of the first embodiment. Garter 86 has a garter flange 94folded onto the top surface 90 of the mandrel, similar to the firstembodiment. Garter flange 94 has an innermost edge 95. Hole 84 insubstrate 82 is sized to be slightly smaller in circumference than theinnermost edge 95 of garter flange 94. Hole 84 may be aligned withinnermost edge 95 when substrate 82 is placed against garter flange 94,as shown in FIG. 8.

FIG. 9 shows a rotatable sealing roll 96 in contact with substrate 82.Rolling contact between sealing roll 96 and the top surface 90 ofmandrel 88 enables sealing roll 96 to progressively bond substrate 82 toa garter flange 94 to form seal 98, using mandrel top surface 90 as ananvil. Garter flange 94 and substrate 82 remain fixed relative to topsurface 90 during this process. Sealing energy, which bonds theinterface between substrate 82 and garter flange 94, may be delivered asheat and pressure by sealing roll 96, from a source not shown.Alternatively, a pressure sensitive adhesive layer, not shown, betweensubstrate 82 and garter flange 94 may be activated by pressure alonefrom sealing roll 96. The material of elastic garter flange 94 may evenbe a pressure sensitive adhesive.

Indeed, there are many known bonding approaches which could be used tosecure garter flange 94 to substrate 82. For example, sealing could beaccomplished instantaneously rather than progressively by pressing asealing die against the entire top surface 90 of mandrel 88. Top surface90 of mandrel 88 may be substantially planar to maximize the seal areaor for construction simplicity. Alternatively, mandrel 88 may have araised outer rim, similar to outer rim 58 shown in FIG. 5, in order tominimize the seal area. Such an outer rim may be continuous in order toprovide a continuous seal, or it may be discontinuous in order toachieve a discontinuous seal. Alternatively, a sealing die may have acontinuous or discontinuous pattern pressing against a substantiallyplanar mandrel top surface.

FIG. 10 shows substrate 82 sealed to a garter 86 being stripped frommandrel 88. The seal 98 between substrate 82 and garter flange 94 mustbe strong enough to enable stripping garter 86 from side walls 92 ofmandrel 88.

Third Preferred Embodiment

In FIGS. 11-14b, there is shown a third preferred embodiment of thepresent invention, which provides a method and apparatus for combining atensioned elastic garter with a substrate, and is generally indicated as100. Embodiment 100 includes a mandrel 102, which has a top surface 104and side walls 106 depending from top surface 104. Top surface 104 mayhave any perimeter shape, as long as it has at least two concaveportions formed by recesses 108 in side walls 106. FIG. 11 shows amandrel 102 with four concave recesses 108. Top surface 104 issubstantially planar and side walls 106 are substantially perpendicularto top surface 104.

FIG. 11 shows a tensioned elastic garter 110 wrapped around mandrel 102.Garter 110 clings tightly to side walls 106 of mandrel 102 due to thetension in the garter. The tension in garter 110 also causes garter 110to span the concave recesses 108. FIG. 11 shows the entire elasticgarter 110 positioned below top surface 104 of mandrel 102.

FIG. 12 shows a substrate 112 placed against the top surface 104 ofmandrel 102. Substrate 112 is shown as transparent for illustrationpurposes, but may be any fabric or film which is sealable to thematerial of elastic garter 110. Garter 110 is made of preferably thesame material as described for the first embodiment of the presentinvention. Substrate 112 is shown in sheet form, but it may also be acontinuous web.

FIGS. 13a and 13b show a substantially planar anvil plate 114 loweredinto contact with substrate 112. Anvil plate 114 extends beyond theperimeter of top surface 104. Also shown are sealing tools 116 whichrise through recesses 108 to intercept the portions of garter 110 whichspan across the recesses. Sealing tools 116 push garter 110 againstsubstrate 112 which are backed by anvil plate 114. In order to preventgarter 110 from sliding off sealing tools 116, either the sealingsurface of the tools is of sufficient size or spring-loaded guide pins,not shown, extend above the sealing surfaces of sealing tools 116 tocontain garter 110. When garter 110 is pinched between the sealing tools116 and substrate 112, garter 110 is gathered randomly by the sealingsurfaces. Garter wrinkles are therefore sealed into the bond betweengarter 110 and substrate 112. Pressure sensitive adhesive, heat fromsealing tools 116, heat from anvil 114, or a combination of them; aswell as other adhesive or thermal bonding systems may act to create abond 118 between garter 110 and substrate 112 at the points wheresealing tools 116 press garter 110 and substrate 112 against anvil plate114.

FIGS. 14a and 14b show anvil plate 114 removed after sealing, andsealing tools 116 stripping substrate 112 and garter 110 off mandrel102. Portions of tensioned elastic garter 110, which are not sealed tosubstrate 112, take straight line paths between sealing points once thegarter has been stripped off the mandrel, due to tension in the garter.Thus, a tensioned elastic pattern is generated, which is predeterminedby the locations of recesses 108, but which may be different from thetop surface perimeter of mandrel 102. That is, the mandrel shape isgenerally larger in circumference than the chordal lengths betweenrecesses. Because the garter assumes a shape smaller than thecircumference of the mandrel, some garter tension is removed after thesubstrate and garter are stripped from the mandrel.

Fourth Preferred Embodiment

In FIGS. 15, 21a, and 21b there is shown a fourth preferred embodimentof the present invention, which provides a method and apparatus forforming a tensioned elastic garter around a mandrel, and is generallyindicated as 120. Embodiment 120 includes an apparatus having a mandrel121 shown in a series of five positions, designated 122, 124, 126, 128,and 130, all having a common centerline 132 and with substantially equalspaced gaps between mandrel positions. Mandrel 121 is preferably ovaland similar to the mandrel design of the first preferred embodiment, asillustrated in FIGS. 1 and 2.

FIG. 15 shows two pair of metering rolls 134 and 136 located in a fixedposition upstream of mandrel position 122. Metering roll pairs 134 and136 feed elastic ribbons 138 and 140 respectively, tangentially tomandrel 121. As mandrel 121 is moved from its initial position 122 toposition 124, the elastic ribbons 138 and 140 are stretched in adirection substantially parallel to the common centerline 132. Elasticribbons 138 and 140 may be made as homogeneous sheets of elastic orlaminates of elastic strands and nonwovens, or any other continuous websof material capable of being stretched. Mandrels are either indexed fromposition to position or they move together at a constant speed.

Moving along with mandrel 121 are clamp pairs 142 and 144. Each clamp ofthe pair 142 also moves perpendicular to common centerline 132 in unisonwith its mate. Each clamp of the pair 144 moves similarly to those ofpair 142 but at a different time in the process. Clamp pair 142 is shownopen in position 146 outside the elastic ribbons 138 and 140, and clamppair 144 is shown closing against the elastic ribbons, thereby pushingthem toward common centerline 132 in position 148. When the mandrel 121reaches position 124, clamp pair 142 moves to position 148 and clamppair 144 moves to position 150.

As the mandrel 121 moves forward, the clamp pairs close on the elasticribbons progressively until both ribbons are clamped at commoncenterline 132, as shown by clamp position 150. When each pair of clampsreach the closed position 150, elastic ribbons 138 and 142 are pressedagainst each other and sealed together by sealing means within theclamps. Also within each pair of clamps is a means for cutting theribbon within the sealed region in order to separate the sealed elasticribbon of one mandrel from that of the adjacent mandrel. A preferredclamp/seal/cut device is shown in FIG. 20. After remaining closed longenough for ribbon sealing and cutting, the closed clamp pairs open asshown in clamp position 152. Once opened, clamp pairs remain open asshown in subsequent positions 154 and 156.

In the clamp/seal/cut process of apparatus 120, the elastic ribbons 138and 140 are progressively wrapped around the side walls of a mandrel toform a complete loop. At clamp position 150, the ribbons 138 and 140 aresealed and cut at the leading end of the mandrel in position 124 and atthe trailing end of the mandrel in position 126. Thus, at mandrelposition 126, a tensioned garter 158 is first formed. If the process ofpreferred embodiments one and two were used to generate a garter flange159, garter flange 159 would be completely formed by mandrel position128.

Elastic ribbons 138 and 140 may be metered in a partially contractedstate at the speed of mandrel 121 traveling along common centerline 132.In this case the tension eventually applied to the ribbons would be afunction of the amount of wrap applied to them around the mandrel 121.The ribbons may also be metered slower than the speed of mandrel travelsuch that stretch occurs during metering. Other tensioning arrangementsare within the scope of the present invention as long as the garter hasbeen tensioned some amount when formed around the mandrel.

At mandrel position 130 the oval mandrel is shown rotated 90°. Dependingon the product application for the elastic garter, it may be required tohave the oval garter oriented differently between the forming processand the downstream substrate securement process. A different mandrelorientation for garter forming may be desirable in order to minimize theamount of stretch imparted to the elastic ribbons as they are wrappedaround the mandrel. When the elastic ribbon is metered parallel to thecommon centerline 132, less stretch is imparted during wrapping if themajor axis of the oval is parallel to the common centerline 132 than ifthe major axis is perpendicular to the common centerline 132. Also,wrapping elastic ribbons around mandrels that are oriented such thatthere is minimum travel of the wrapping mechanism is important for highspeed garter forming. FIG. 15 shows that if mandrel 121 is pivotableabout its top surface center, it may be rotated at position 130 in orderto meet both the garter forming and securement requirements.

FIGS. 21a and 21b show an alternative for elastic ribbon constructionfor the fourth preferred embodiment 120. Instead of a uniformlycontinuous elastic ribbon, the alternative ribbon preferably hasunbonded locations which have no elastic in them, equally spaced alongthe length of each elastic ribbon. Such unbonded locations may beregistered with the gaps between mandrels so that the ribbon sealing andcutting operations there do not have to seal and cut through elastic. Ifthe tensioned elastic ribbons are made of a trilaminate of polypropylenenonwoven outer layers 135 and 137 and natural rubber elastic strands 133bonded therebetween, it is preferable to avoid heat sealing throughnatural rubber, because the presence of such rubber weakens the sealbetween the two tensioned elastic ribbons bonded around the mandrels.

A trilaminate 140 made of nonwoven outer layers 135 and 137 and aplurality of natural rubber elastic strands 133 is preferablyconstructed by applying intermittently an adhesive to the stretchedstrands 133 when they are combined with the outer layers. In order toprovide unbonded locations in the elastic ribbons, having a length A ofabout 1 to 3 inches (2.5 mm to 7.6 mm) long, in which there are noelastic strands, the laminate 140 is first bonded together with theunbonded locations having no adhesive applied. That is, stretchedelastic strands 133 extend through each unbonded location, bonded ateach side of the unbonded location but not bonded within it. Followingsuch interrupted bonding, each tensioned elastic ribbon 138 or 140 isexposed to a compression process which bursts the elastic strandspassing through each unbonded location.

In this process a blunt tool 139 presses against the trilaminate 140backed by a substantially planar anvil surface 141. A fixed gap betweentool 139 and anvil 141 of 0.001 inches (0.0025 mm) generates a localizedpressure of 30,000 to 40,000 psi (2041 to 2722 atm.), which issufficient to burst the plurality of natural rubber strands 133 withoutcutting the polypropylene nonwoven layers 135 and 137. Once the elasticstrands 133 are burst, they contract to the edges of the unbondedlocation, leaving an unbonded location 143 in which there are no elasticstrands passing through it.

Fifth Preferred Embodiment

In FIG. 16, there is shown a fifth preferred embodiment of the presentinvention, which provides a method and apparatus for both forming andcombining a tensioned elastic garter with a substrate, and is generallyindicated as 160. Embodiment 160 includes a continuously rotating drum162 supported and driven by a support means and drive means not shown.Mounted to drum 162 are oval mandrels 164 of the design described inpreferred embodiment one. Mandrels 164 are connected to pivot shafts166, which extend radially from drum 162, and they are equally spacedalong a common centerline wrapped about the circumference of drum 162.In this configuration the garter forming process of preferred embodimentfour and the combining process of preferred embodiment one are combinedto operate continuously at high speeds, as is desirable for disposablediaper manufacturing.

Mandrels 164 have top surfaces 168 and side walls 170 similar to topsurface 34 and side walls 36 of mandrel 32. Mandrels 164 also haveraised outer rims 172 with beads 174 for ultrasonic bonding purposes,however outer rim 172 and peak 174 have top surface curvatures whichpermit their surfaces to remain tangential to an ultrasonic horn 180,which is externally mounted from drum 162, as the mandrels rotate pastthe stationary horn. Because the pivoting of mandrels 164 is desired asexplained heretofor, the curvatures of outer rim 172 and peak 174 havean axis of curvature 176 coincident with the axis of rotation of thedrum when the mandrels 164 are pivoted for ultrasonic horn engagement.The oval mandrels are pivoted such that their major axes of ovality 178are parallel to curvature axis 176 when the mandrels 164 are pivoted forultrasonic horn engagement. Elsewhere around the drum mandrels 164 arepivoted perpendicular to their orientation for ultrasonic hornengagement. In the latter orientation mandrels are oriented forformation of elastic garters about them.

FIG. 16 shows tensioned elastic ribbons 182 and 184 metered tangent tomandrel side walls 170. Tensioned elastic ribbons 182 and 184 have upperportions 186 and 188 and lower portions 190 and 192, respectively.Tensioned elastic ribbons 182 and 184 are metered such that whenprogressively wrapped around mandrels 164, upper portions 186 and 188are positioned above top surface 168 of each mandrel. Garters 194 arecreated by the method of the fourth preferred embodiment of the presentinvention; ie., progressively clamping ribbons 182 and 184 togetherbetween mandrels, and then sealing and cutting the ribbons between themandrels. The elastic ribbons are preferably made with unbondedlocations having no elastic rubber strands passing through them, asdescribed in preferred embodiment four, so that sealing and cuttingbetween mandrels is optimized.

FIG. 16 shows successive mandrels 164 having elastic ribbons 182 and 184progressively pushed together by clamp pairs 196 and 198, which areoperated by air cylinders mounted to drum 162. Although clamp pairsoperate between each mandrel, only two clamp pairs are shown in FIG. 16for clarity. Air may be delivered to a manifold for air cylinderoperation through a rotary joint at the drum axis of rotation andthereafter valved and exhausted to and from cylinders, as is commonlyknown in the art. A stationary manifold shoe may be placed against theside walls of the rotating drum to deliver air under pressure at theappropriate time in the drum cycle, as is also commonly known in theart. Alternatively, clamping mechanisms may have ball screw drives, orthey may be cam operated, or a combination of air pressure and cammingmay be used for actuation.

As explained for the first preferred embodiment of the presentinvention, upper portions 186 and 188 of elastic ribbons 182 and 184fold over onto raised outer rims 172 of mandrels 164 so that whengarters 194 are wrapped about mandrels 162, garter flanges 200 are alsoformed, due to the tension in upper portions 186 and 188. Meanwhile,lower portions 190 and 192 of tensioned elastic ribbons 182 and 184cling to the side walls 170 of mandrels 164 to hold the garters in placefor garter-to-substrate sealing.

After garter formation, oval mandrels 164 may be rotated 90° about theirpivot shafts 166. A substrate web 202 is thereafter introducedtangentially to the circumference of drum 162 by passing it over roll204. Substrate web 202 travels at the same speed as outer rims 172 ofmandrels 164 past stationary ultrasonic horn 180. As mandrels 164 passultrasonic horn 180, the ultrasonic horn vibrates radially to drum 162,pressing substrate 202 and garter flange 200 together against mandrelrim 172 of each passing mandrel. Outer rims 172 preferably have peaksurfaces, not shown, against which ultrasonic horn 180 presses in orderto fusion-seal the garter flange 200 to the substrate 202 with aweakened seal edge inside the oval bond. The vibrational energy istransmitted to the interface of the substrate 202 and garter flange 200generating a continuous fusion-seal wherever rim 172 supports thesubstrate and garter flange as an anvil surface. At the peak surfacesthe fusion-seal is thinned to a glassine state, thereby weakening anedge of the fusion-seal.

Once a fusion-seal is formed between substrate 202 and garter flange200, vacuum is applied to the top surface 168 of mandrel 164 throughholes 206 from a vacuum source not shown. As with air delivery, fixedexternal manifolds sliding against drum side walls or rotary joints maybe employed to deliver vacuum, as is commonly known in the drum andturret machine art.

The vacuum pulls a portion .of substrate 208 inside the oval fusion-sealagainst top surface 168 of the mandrel 164. During the application ofvacuum, substrate 202 passes over another roll 210. The path ofsubstrate 202 away from drum 162 acts to strip garters from the sidewalls 170 of mandrels 164 while vacuum holds substrate portion 208against top surface 168. The action of stripping the substrate from themandrel while holding the material inside the garter to the mandrelbreaks the weakened edge of the fusion-seal such that a substrate hole212 is formed inside the garter 194.

A portion of the garter flange 200 inside the fusion-seal remainsattached to substrate portion 208 which continues to be held by mandrelvacuum after stripping. Once stripping is complete, vacuum is exhaustedand compressed air blown through holes 206 to eject substrate portion208. Substrate portion 208 is collected by a scrap removal system notshown. Mandrel 164 is then pivoted 90° to its garter forming position sothat the cycle may be repeated about drum 162.

FIG. 17 shows a partial side view of drum 162 illustrating thetangential feeding of an elastic ribbon 182 to side walls 170 ofmandrels 164. Each mandrel has a pivot shaft 166 connecting mandrel 164to drum 162. Pivot shafts 166 extend radially from drum 162 and aredriven by means not shown. Such means may be individual shaft motors,for example, or a gear train driven from a stationary ring gear insidethe drum. Such drives are well known in the art.

The drum process embodiment illustrated by FIG. 16 could also be appliedto preferred embodiment two if ultrasonic horn 180 were replaced withsealing roll 96.

Clamp pairs 196 and 198 are illustrated by trapezoids located betweenmandrels in FIG. 17. FIG. 18 shows a partial cross-section of drum 162,illustrating clamp pair 196 and its air cylinders supported from thedrum and elastic ribbons 182 and 184 adjacent mandrel 164 prior toclamping. Elastic ribbons 182 and 184 have upper portions 186 and 188respectively, positioned above top surface 168 and outer rim 172 ofmandrel 164.

FIG. 19 is an enlarged view to better illustrate the position of elasticribbon 182 relative to mandrel 164. Also shown in FIG. 19 is thepreferred construction of the elastic ribbons. Elastic ribbon 182 has asingle strand of elastic 220 sandwiched between two webs of nonwoven 222at its upper portion 186. At its lower portion 190, elastic ribbon 182has five strands of elastic 220 sandwiched between the two webs ofnonwoven 222. This arrangement provides sufficient tension in upperportion 186 to cause the upper portion 186 to fold over onto the outerrim 172 and top surface 168 of mandrel 164 when the ribbon is wrappedaround the mandrel. It also provides sufficient tension in lower portion190 to cling to the side walls 168 of mandrel 164. The gap between thebottom five elastic strands and the top elastic strand provides spacefor sealing garter flange 200 to substrate 202 without sealing throughthe elastic strands.

FIG. 20 is a cross-section of one clamp 230 of clamp pair 196 toillustrate the mechanism that clamps, seals, and cuts elastic ribbons182 and 184. Clamp 230 has yoke 232 slidably supported on stepped aircylinder rod 234. The end surfaces 236 of yoke 232 are the clampingsurfaces. Inside yoke 232 is a sealing die 238 connected to air cylinderrod 234 via insulating block 240. Sealing die 238 has a cartridge heater242 energized by a source not shown. Sealing die 238 has two sealingsurfaces 244 which are pressed against the elastic ribbons 182 and 184after the ribbons are clamped by end surfaces 236. A compression spring250 biases yoke 232 outward such that clamping surfaces 236 areinitially positioned slightly beyond sealing surfaces 244. Betweensealing surfaces 244 is an insulating block 246 supporting a nichromewire 248. The clamping force is a function of spring compression whilesealing force is a function of air cylinder pressure. The opposingsealing die of each pair has a flat heated sealing block instead ofseparate sealing surfaces 244 and nichrome wire 248. Nichrome wire 248is energized from a source not shown to cause it to heat above the melttemperature of the elastic ribbons and thereby cut the elastic ribbonswithin the sealed region. When the sealing dies are retracted, elasticribbons 182 and 184 remain sealed together on either side of the heatednichrome wire. When the clamps are opened by further retraction of theair cylinders, the sealed ribbons snap to their respective mandrels.

Exemplary Construction of the Fifth Preferred Embodiment

The elastic ribbons 182 and 184 of the present invention are preferablya trilaminate construction as shown in FIG. 19. The width of outer layer220 is 1.88 inches (47.75 mm), and it is made of polypropylene nonwoven.There are six elastic strands 222 spaced approximately as shown, andthey are about 2.5 mm in diameter unstretched, and made of naturalrubber. The laminate may have two separate web pieces or have one pieceof web 220 folded in half at the bottom portion. The laminate is bondedtogether intermittently by pressure sensitive adhesive. The laminatepreferably has a 130 percent elongation when fully stretched.

The drum 162 of the present invention has 18 mandrels 164, each mountedat a 13 inch (330 mm) pitch distance about the drum. Each mandrel 164has a major oval dimension of 11.70 in. (297.2 mm) and a minor ovaldimension of 8.88 in. (223.5 mm). There is a 1.3 inch (33 mm) gapbetween adjacent mandrels. Mandrels are preferably made of steel with ahardened top surface. Each mandrel has a top surface 168 and side walls170 depending therefrom at an angle of about 285° so that the lowerportion of garter 194 clings to the mandrel side walls without slippingoff as tension in the upper portion of garter 194 forms the garterflange 200. The ribbons 182 and 184 are positioned relative to themandrels such that the top surface 168 lies about midway between theupper portion elastic strand and the closest bottom portion elasticstrand within the laminate.

As shown in FIG. 16, the oval mandrels preferably have their major axesaligned parallel to the mandrel travel during garter formation. Theelastic ribbons are preferably metered by rubber on steel metering rollpairs (not shown) at the mandrel tangential speed or slightly faster sothat the percent elongation imparted to each of them is slightly lessthan their 130% limit when the garter is formed around the mandrel. The2.5 inch (63.5 mm) bore ribbon sealing air cylinders are pressurized toabout 80-90 psig (5.4-6.1 atm.) and press the sealing dies againstelastic ribbons 182 and 184 across their width to seal them. Dietemperature is about 160° C. and sealing time is approximately 0.1seconds. The 0.062 inch (1.575 mm) diameter nichrome wire is heated to165°-170° C. The clamp force is about 3.4 pounds (15.1 Newtons). Sealingdies are made of C18400 chrome copper and have surfaces coated withelectroless nickel codeposited with teflon to a 0.0003-0.0005 inch(0.0076-0.0127 mm) thickness.

Mandrels 164 are rotated 90° after garter forming in order to positionthe oval major axis 178 perpendicular to the direction of mandrel travelfor desired substrate bonding orientation.

Substrate 202 is a 25 gmms/square yard polypropylene nonwoven of 19 in.width, which is metered under 100 grams/lineal inch (39 gm/cm) tensiontangentially to and at the same speed as curved mandrel top surfaces168. This tangential speed is preferably 320 feet/minute (1626 mm/sec).Mandrel 164 has raised continuous outer rim 172, which is 0.100 in.(0.254 mm) above top surface 168 and 0.100 in. (0.254 mm) in width.Ultrasonic horn 180 is mounted tangentially to the mandrel top surfacepath, which has a radius of curvature of 37.53 inches (953.26 mm). Thehorn has a flat surface 0.64 inches (16.26 mm) wide in the direction ofdrum travel. The ultrasonic system has a vibration frequency is 20,000Hertz and a horn interference setting of 0.005 inches 0 0.127 (mm).Contact time is approximately 0.01 seconds and maximum power output isused from a model no. 180P ultrasonic power source, available fromBranson Ultrasonic Co. of Danbury, Ct.

Outer rim 172 has continuous peak 174 at its center to weaken the fusionseal at that point by compressing the substrate and garter flange verythin. The sealing surface has two angled surfaces blended with a 0.03inch (0.76 mm) radius curved surface between them. The angled surfacesare both at about 12°-15° from horizontal toward the base of the rim172.

In order to remove the portion of the substrate and garter flange 208from inside the oval seal, a 20 inches of water (508 mm of H2O) vacuumis applied to the substrate at the top surface 168 of the mandrel aftersealing has been completed. This vacuum is sufficient to hold portion208 while substrate web 202 is pulled over roll 210 and away from themandrel 164. The bond between substrate 202 and garter flange 200outside the weakened edge is sufficient to pull the garter with thesubstrate off the mandrel.

While particular embodiments of the present invention have beenillustrated and described, it will be obvious to those skilled in theart that various changes and modifications may be made without departingfrom the spirit and scope of the invention, and it is intended to coverin the appended claims all such modifications that are within the scopeof the invention.

What is claimed is:
 1. A method of combining a tensioned elastic garterwith a substrate, said method comprising the steps of:a) wrapping atensioned elastic garter about a mandrel, said mandrel having a topsurface and side walls depending from said top surface, said tensionedgarter positioned on said mandrel below said top surface and about saidside walls of said mandrel, said side walls having recessed portionsacross which said tensioned garter spans; b) placing a substrate againstsaid top surface of said mandrel; and c) securing said tensioned garterto said substrate with sealing tools which are disposed in said recessedportions of said mandrel side walls while said tensioned garter is heldby said mandrel in a predetermined shape.
 2. The method of claim 1wherein the step of securing said substrate to said tensioned elasticgarter includes:a) backing said substrate with an anvil surface opposingsaid mandrel top surface; b) intercepting said tensioned garter withsaid sealing tools disposed in said recessed portions of said mandrelside walls; and c) pressing said tensioned garter against said substratebacked by said anvil surface to enable securement of said tensionedgarter to said substrate by a sealing means wherever pressing by saidsealing tools occurs.
 3. The method of claim 2 wherein said sealingmeans is a pressure sensitive adhesive between said tensioned garter andsaid substrate.
 4. The method of claim 2 wherein said sealing means isthermo bonding between said tensioned garter and said substrate, saidsealing tools providing sufficient heat and pressure over sufficienttime to seal said tensioned garter to said substrate.
 5. The method ofclaim 4 wherein said garter is sealed to said substrate only at sealingspots where said sealing tools pressed said garter against saidsubstrate backed by said anvil, so that when said garter is strippedfrom said mandrel, a portion of said tensioned elastic garter betweensaid sealing spots takes a straight line path between said sealingspots.
 6. The method of claim 1 further comprising the step of strippingsaid tensioned elastic garter from said mandrel side walls by movingsaid substrate away from said top surface of said mandrel after saidgarter is secured to said substrate.
 7. The method of claim 2 furthercomprising the step of stripping said tensioned elastic garter from saidmandrel side walls by pushing said garter with said sealing tools abovesaid top surface of said mandrel after said anvil is removed.
 8. Amethod of combining a tensioned elastic garter with a substrate, saidmethod comprising the steps of:a) wrapping a tensioned elastic garterabout a mandrel, said mandrel having a top surface and side wallsdepending from said top surface, said tensioned garter positioned onsaid mandrel below said top surface and about said side walls of saidmandrel, said side walls having recessed portions across which saidtensioned garter spans; b) placing a substrate against said top surfaceof said mandrel; and c) backing said substrate with an anvil surface; d)raising sealing tools through said recessed portions of said mandrelside walls to intersect said tensioned garter spanning said recessedportions; e) pressing said tensioned garter against said substratebacked by said anvil surface to thermo bond said tensioned garter tosaid substrate wherever pressing by said sealing tools occurs, therebycreating sealing spots; and f) stripping said tensioned garter from saidside walls of said mandrel so that portions of said garter between saidsealing spots take straight line paths between said sealing spots.
 9. Amethod of combining a tensioned elastic garter with a substrate, saidmethod comprising the steps of:a) wrapping a tensioned elastic garterabout a mandrel, said mandrel having a top surface and side wallsdepending from said top surface, said tensioned garter positioned onsaid mandrel below said top surface and about said side walls of saidmandrel, said side walls having recessed portions across which saidtensioned garter spans; b) placing a substrate against said top surfaceof said mandrel; and c) backing said substrate with an anvil surface; d)raising sealing tools through said recessed portions of said mandrelside walls to intersect said tensioned garter spanning said recessedportions; e) pressing said tensioned garter against said substratebacked by said anvil surface to adhesively bond said tensioned garter tosaid substrate wherever pressing by said sealing tools occurs, therebycreating sealing spots; and f) stripping said tensioned garter from saidside walls of said mandrel so that portions of said garter between saidsealing spots take straight line paths between said sealing spots.